International Journal on Recent and Innovation Trends in Computing and Communication

Volume: 3 Issue: 8

ISSN: 2321-8169
5132 - 5135

_______________________________________________________________________________________________

Design & Development of Three Roller Sheet Bending Machine

Mahesh Gadekar1, Mr. Amol 2 Student1, Asst.Prof2
Dept. of Mechanical Engineering, AbhaGaikawadPatil Engineering College,
Nagpur, Maharashtra, India
Abstract:- Metal forming can be defined as a process in which the desired size and shapes are obtained through plastic deformation of a material
without any significance loss of material. Bending is a metal forming process in which straight length is transformed into a curved length. Roller
forming is a continuous bending operation in which a long strip of metal is passed through consecutive sets of rollers, until the desired cross
sectional profile is obtained.
The roller bending process usually produces larger parts of cylindrical or conical cross sections in large quantity. Normal practice of the roller
bending still heavily depends upon the experience and skill of the operator. Trial and Error is a common practice in the industry. Rolling process
always began with crucial operation of pre bending both ends of the work piece. This operation eliminates flat spot when rolling a full
cylindrical shape and ensures better closure.

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1.

INTRODUCTION

Roller bending process can be used to deform a sheet or

plate to hollow shapes of constant (i.e. cylindrical, elliptical)
or varying cross sections like cone frustum. Cylindrical and
conical shells are the basic components used for the various
engineering applications like cylindrical tanks, boiler
chambers, heat exchanger shells, pressure vessels, tunnels,
etc. The process can be performed using many materials
such as carbon and alloy steels, aluminium alloys and
titanium alloys. Rolling machines with both three and four
rolls are indispensible to the production of cylinders with
various curvatures. The rolling process is usually performed
by a three roll bending machine often called as pyramid
type, because of the peculiar arrangement of the three
rollers. The entire process of the roll bending may be
divided into three steps: namely,
1. Positioning of blank sheet or plate.
2. Lowering of the center roller.
3. Feeding of the plate.
In the very first step, a flat blank sheet is fed into the
machine by two rotating side rollers until the sheet is
properly positioned. In the second step, center roller is
displaced downward causes bending of the sheet. In the final
step, two side rollers rotate again, so that the sheet is bent
continuously.
The rolling process always began with the crucial operation
of pre bending both ends of the sheet. This operation
eliminated flat spots when rolling a fall cylindrical shape
and ensured better closure of the seam. The success of three
roller bending process heavily depends on the experience
and skill of the operator.

2.

LITERATURE SURVEY

M. Hua et al [1] developed, in the paper, an analytical

model to study the mechanics of continuous plate edge
bending mode of the four roll bending process, solving
governing differential equation for the large deflection
of an elastoplastic thin plate with an arbitrary strain
hardening law for the material. The effect of material
strain hardening on the mechanics is also studied and
compared with those for a perfectly plastic material.

M. Hua et al[2] discussed design consideration,

working principle and bending mechanisms the four
roller bending machine. Generalised procedure of four
roller bending machine is also explained.

Jong Gye Shin et. al [3] in the paper, developed a

logical procedure to determine the center roller
displacement, in the three roll bending process, which
is required in the fabrication of curved rectangular
plates with a desired curvature. To this end, the
mechanics of the process was analyzed by both
analytical and finite element approaches. Comparisons
of the results reveal that a simple analytical procedure,
based on the beam theory, yields a reasonably accurate
relationship between the center roller displacement and
residual curvature. With further development and
refinement, the procedure proposed in this work has
great promise for practical application, particularly for
the automation of the process.

Dr. C. C. Handa et. al [4] discussed about the

productivity analysis of manually and power operated
sheet bending machine considering time required to
complete one pipe, total expenditure required to
manufacture one pipe, number of operators and labors
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_______________________________________________________________________________________

International Journal on Recent and Innovation Trends in Computing and Communication

Volume: 3 Issue: 8

ISSN: 2321-8169
5132 - 5135

_______________________________________________________________________________________________
required during both operations, etc. Limitations of the
manually operated sheet bending process over power
operated sheet bending machine is also discussed.

P.G. Mehar [5] in his M. Tech Thesis studied the

manually operated and power operated sheet bending
machine. Experimentations were conducted on sheet in
order to measure actual no. of passes, time required to
complete bending process etc. Also, productivity of
sheet bending process is analyzed in depth. Design of
various components of power operated sheet bending
machine considering various theories of failure in
elastic region and values for bending force, power
required, spring back radius etc. for different
diameters, thicknesses and width of sheet metal has
been determined.
3.

PROBLEM IDENTIFICATION:

Manufacturing is a field of transferring raw material into

finished goods. There are many manufacturing firms that
can be found such as automobile factories, bakery factories,
electrical factories, etc. Many of the factories produce their
products in mass production. So, these factories or
companies are competing each other to get their products in
the market. Therefore, they must have good manufacturing
facilities to improve their productivity. Except this machine
is power operated machine so that it requires motor, gear
bore, and gearing arrangement. Here motor supplies the
power to the gear box. Now this gear box transmits the
power to the gears and at last it transmits to the roller. In the
process the sheet is insert in between the lower rollers and
upper roller than with the help of screw given at both of
machine is lowering by revolving with rod. Now this screw
roller at the end, and when screw rotates in downward
direction then roller is also lowered their position. Now
much distance the upper roller should came or the setting of
roller is depends upon the thickness & diameter of sheet
which is to be bend in the machine. Once the setting of
screw is over, operator start the machine, the sheet passes
towards the other side of the machine. After the one pass,
again the setting of screw is to be done if requires and next
pass is again start; it is restricted up to the cylindrical pipe is
made. After getting a cylinder pipe, some positions of pipe
is welded called tacking. After the welding, the welded
position of pipe is passing through the roller. Then this pipe
is removed from the machine by removing the base after
removing the screw the side body is tilled to the side. Before
tilting the body, one rod is inserted in between the upper
roller and lower roller, and then the body is tilled and
removes the pipes from the machine.

The manual process causes fatigue to labors, lowers

the efficiency of labors and there by lowers the working
efficiency of sheet bending operation. So the main causes
get a desired curve on a 3 roller sheet bending machine, it is
generally used by apply force by using a screw jack which
is approximate & depends on experimentation and labor
skill, so that it is a trail and error method carried out by
skilled labor because of this applied force may vary person
to person and may get different sizes of the cylinder shells.
3.1 Study Objective of Research
This research pertains literature review reveals that trial and
error experience of operator is still a common practice in the
industry. Sequential bending on a roller bending machine is
widely used in practice but involves very high amount of
labour in marking, locating, shifting and inspecting the sheet
after each sequential bend. An operator must have
knowledge of different machine parameters to obtain
cylinders with desired diameter. Overall objective of the
research work is

Modeling and Simulation of sheet Bending Machine.

Force Analysis of Sheets with Different Materials
and Different Thickness.

3.2 Research Methodology

It involve the study of present 3 roller sheet bending
machine.. In this we will first identify the mechanical
elementwill find out the dimension of the machine
component from vidarbha Industry.

Figure 3.1 roller sheet bending machine form vidharbha

Industry
1.
2.
3.

Productivity analysis of manually operated and

power operated sheet bending machine
Modeling of metal sheet bending machine.
Simulation of sheet metal bending machine with
different materials.
5133

IJRITCC | August 2015, Available @ http://www.ijritcc.org

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International Journal on Recent and Innovation Trends in Computing and Communication

Volume: 3 Issue: 8

ISSN: 2321-8169
5132 - 5135

_______________________________________________________________________________________________
4.
5.

Forces analysis of metal sheet by analytical

method.
Bending force analysis of metals sheet during
bending operation by software approach .
4.

MODELLING:

The importance of modeling and simulation in

manufacturing technology is increasing due to the need for
continuous reduction of development times. This
necessitates the optimization of the production processes,
the enhancement of product quality and a reduction of costs.
The application of numerical modeling is especially resorted
to in the development of new production methods and in the
use of new materials. Specialized software solutions are
available to optimize the design of castings (solidification
analysis), welding process (resistance welding, gas metal arc
welding), heat treatment and metal forming (sheet metal
processing, tube bending, extrusion, rolling, drawing,
forging etc).
4.1Steps Of Modeling

4.3 Orthographic Projection of 3 roller bending

machine
5.

RESULTS & DISCUSSIONS

After Design of three roller bending machine completed for

sheet thickness of 0.8mm to 1.5mm bending of sheet metal..
These results are changing according to the material and
according to the loading condition and finally depend upon
the thickness of the sheet.
Materials are used for Design of three roller bending
machine are as follows
1) Cold rolled sheet metal (CRCA)
2) Hot rolled sheet metal (HR)

4.1 Isometric View of 3 roller sheet bending machine

Thickness of sheet usedpractically varies from 0.8mm to 1.5

mm. The experimental performed on sheet having
dimensions (250 x 400 ) mm . The power gainedbyupper
roller through different gear drive system and this load is
applied on the sheet.A sheet passes through between the
upper and lower roller the sheet goes bend.This process
iscontinue till therequired result is obtained.
The stress induced on the sheet is calculated by the
analytically as well as virtually using analysis software. For
virtual analysis CAD MODEL is generated in creo
parametric 2.0 and converted into iges format .
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4.2 Exploded View of 3 roller sheet bending machine

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International Journal on Recent and Innovation Trends in Computing and Communication

Volume: 3 Issue: 8

ISSN: 2321-8169
5132 - 5135

_______________________________________________________________________________________________
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